UNIT 2

VARIABLE STRESSES
 Stress Concentration
• The fundamental equations are
• In design of machine elements, the derived from number of assumptions.
fundamental equations are
• Material is homogeneous
• No discontinuities
• Plane section remain plane
• In practice, discontinuities and abrupt changes
in cross section are unavoidable due to oil holes,
grooves, keyways, splines screw threads and
shoulders etc.
• In changes in area, a sudden rise in the
magnitude of stresses in the vicinity of the hole.
• The irregularity in the stress distribution caused
by abrupt changes of form is called stress
concentration.
 Stress Concentration
• The theoretical or form stress concentration factor is defined as the ratio of the
maximum stress in a member (at a notch or a fillet) to the nominal stress at the
same section based upon net area.
• The value of Kt depends upon the material and geometry of the part.
• Mathematically, theoretical or form stress concentration factor,

• Stress concentration due to • Theoretical Stress Concentration

Holes and Notches: Factor:
 Methods of Reducing Stress Concentration
(1) Additional Notches and Holes in (2) Fillet Radius, Undercutting and
Tension Member Notch for Member in Bending
A single notch results in a high stress • The shoulder creates a change in cross-
concentration. The severity of stress section of the shaft, which results in stress
concentration is reduced by concentration.
(a) Us multiple notches • (a) Fillet radius (b) Under cut
(b) Drilling additional holes • (c) Notch
(c) Removal of undesired material
 Methods of Reducing Stress Concentration
(3) Drilling Additional Holes for (4) Reduction of Stress concentration in
Threaded Members
shaft
- The force flow line is bent as it passes
from the shank portion to threaded portion
of the component.
 Stress Concentration
• Problem: Taking stress concentration in
to account find the maximum stress
induced when a tensile load of 20 kN is
applies to:
• (i) A rectangular plate 80 mm wide
and 12 mm thick with a transverse
hole of 16 mm diameter
• (ii) A stepped shaft of diameters 60
mm and 30 mm with a fillet radius
of 6 mm
 Stress Concentration
• Solution:
• (i) Rectangular Plate: (PSG DB – 7.10)

= 19.53 N/mm2

• From graph, a/w = 16 / 80 = 0.2

• Stress concentration Factor Kt = 2.5
• max = 0 x KT = 48.825 N/mm2
 Stress Concentration
• (ii) Fillet: (PSG DB – 7.11)

Nominal Stress = P / A = 20 x 103 / ((/4)(30)2)

= 28.29 N/mm2

• max = 0 x KT
• From graph, r/d = 0.2; D/d =2
• Stress concentration Factor Kt = 1.5

• max = 0 x KT = 28.29 x 1.5 = 42.44 N/mm2

A non-rotating shaft supporting a load of 2.5 kN. The shaft is made of brittle material, with an ultimate tensile
strength of 300 N/mm2. The factor of safety is 3. Determine the dimensions of the shaft.

P = 2.5 kN Sut = 300 N/mm ² FOS= 3

Step I Calculation of permissible stress

max =Sut/FOS=300/3 =100 N/mm ²
Step II Bending stress at fillet section. Due to symmetry, the reaction at each bearing is
1250 N. The stresses are critical at two section
(i)at the centre of span, and (ii) at the fillet. At the fillet section,

Kt = 1.61(from DDB 7.11)

 Step III Bending stress at centre of the span

Step IV Diameter of shaft

it is seen that the stress is maximum at the fillet section. Equating it with permissible stress,
 Member Subjected to Variable Stresses
(PSG DB – 7.1)
• Machine parts are subjected to variable or alternating loads like fluctuating or fatigue
loads.
• Example: Axles, Shafts, Crankshafts, Connecting rods, Springs, Pistons, Gear etc.

It fluctuates between two The repeated stress varies in a The reversed stress varies in
limits – maximum & sinusoidal manner with respect a sinusoidal manner with
minimum. The stress can to time, but the variation is from respect to time, but it has
be tensile or compressive. zero to some maximum value. zero mean stress.
 Fatigue Failure
• In static loading, the material starts failures after yielding stress.
• Some times, the material fails within the yield stress due to fatigue load or
fluctuating load. That is called as fatigue failure.

• Fatigue failure is defined as time delayed fracture under cyclic loading.

• In static load, there is sufficient plastic • In fatigue failure is sudden and total.
deformation prior to failure.
 Endurance Strength or Limit

• The fatigue or endurance limit of a material is defined as the maximum

amplitude of completely reversed stress that the standard specimen can
sustain for an unlimited number of cycles without fatigue failure.

• The fatigue life is defined as the number of stress cycles that the standard
specimen can complete during the test before the appearance of the first
fatigue crack.
 S-N curve (PSG DB – P 7.5)
• The S-N curve is the graphical representation
of stress amplitude (f) verses the number of
stress cycles (N) before the fatigue failure on a
Log – Log graph.
 Factors to be Considered while Designing Machine
Parts to Avoid Fatigue Failure
1. The variation in the size of the component should be as gradual as
possible.
2. The holes, notches and other stress raisers should be avoided.
3. The proper stress de-concentrators such as fillets and notches should be
provided wherever necessary.
4. The parts should be protected from corrosive atmosphere.
5. A smooth finish of outer surface of the component increases the fatigue
life.
6. The material with high fatigue strength should be selected.
7. The residual compressive stresses over the parts surface increases its
fatigue strength.
 Low and High Cycle Fatigue

• Any fatigue failure when the number of stress cycles are less than 1000, is called low-cycle fatigue.
• Example: Springs, ball bearings
• Any fatigue failure when the number of stress cycles are more than 1000, is called high-cycle fatigue.
 Notch Sensitivity
• Notch sensitivity is defined as the susceptibility of a material to succumb to the
damaging effects of stress raising notches in fatigues in fatigue loading.
Where
0 = Nominal stress as obtained
by elementary equations
Increase of actual stress over nominal Actual stress = Kf 0
stress = Kf 0 - 0 Theoretical stress = Kt 0
Increase of theoretical stress over nominal Kt – Theoretical stress concentration factor;
stress = Kt 0 - 0
Kf – Fatigue stress concentration factor
(i) No sensitivity q = 0 and Kf = 1
(ii) Fully sensitive q = 1 and K f = Kt
 Factors to be consider for Fatigue Stress
(i) Surface Finish Factor:It is impractical to provide very good surface finish for
the actual component.
The endurance limit is reduced due to introduction of stress concentration at
these scratches.
The surface finish factor takes into account the reduction in endurance limit due
to the variation in the surface finish between the specimen and the actual
component.
It should be noted that ultimate tensile strength is also a parameter affecting the
surface finish factor. High strength materials are more sensitive to stress
concentration introduced by surface irregularities. Therefore, as the ultimate
tensile strength increases, the surface finish factor decreases.
Shigley and Mischke have suggested an exponential equation for the surface
finish factor.
Ka =
 Factors to be consider for Fatigue Stress
• (ii) Size Factor: • (iii) Reliability Factor:
 Factors to be consider for Fatigue Stress
• (iv) Load Factor:
When the component is subjected to an axial fluctuating load, the
entire cross section is uniformly stressed to the maximum value. But beam
and shaft, the stress is zero at centre of cross section.
Therefore, endurance limit in axial loading is lower than the beam or
shaft.
For axial loading, e)a =0.8 e

• (V) Modifying Factor to Account for Stress Concentration:

Kd = 1/Kf ; Kf = 1 + q(Kt-1)
 Infinite – Life Problems (Reversed Load)
• Problem: A plate made of steel 20C8 (ut = 440 N/mm2) in hot rolled(a=57.7 and b=-0.718) and
normalized condition is shown in fig. It is subjected to a completely reversed axial load of 30 kN.
The notch sensitivity factor “q” can be taken as 0.8 and the expected reliability is 90%. The size
factor is 0.85. The factor of safety is 2. Determine the plate thickness for infinite life.
• Solution:
• Given: P = 30 kN; ut = 440 N/mm2; FOS = 2; R = 90%;
q = 0.8; Kb = 0.85
• Step – 1: Endurance Limit Stress for Plate
’ut = 0.5 x ut = 220 N/mm2 Ka = 0.67 (Hot Rolled); Kb = 0.85
For 90% reliability, Kc = 0.897 (From Table);
For d/w = 10/50 = 0.2; From fig. Kt = 2.5; e =KaKbKcKd ’ut
Kf = 1+q(Kt-1) =1+0.8(2.5-1) = 2.2 =0.67(0.85)(0.897)(0.453)(220)
= 50.9 N/mm2
Kd = 1 / Kf = 1 / 2.2 = 0.453
 Infinite – Life Problems (Reversed Load)
For axial Load; e)a = 0.8 e = 40.72 N/mm2
• Step – 2: Permissible Stress Amplitude

• Step –3: Plate Thickness

A rotating bar made of steel 45C8 (Sut = 630 N/mm2) is subjected to a completely reversed
bending stress. The corrected endurance limit of the bar is 315 N/mm2. Calculate the fatigue
strength of the bar for a life of 90,000 cycles.
 COMBINED STEADY AND VARIABLE
•STRESS
The failure points from fatigue tests made with
different steels and combinations of mean and
variable stresses are plotted in Fig. 6.15 as
functions of variable stress (σv) and mean
stress (σm).
• The most significant observation is that, in
general, the failure point is little related to the
mean stress when it is compressive but is very
much a function of the mean stress when it is
tensile.
• In practice, this means that fatigue failures are
rare when the mean stress is compressive (or
negative).
• Therefore, the greater emphasis must be given
to the combination of a variable stress and a
steady (or mean) tensile stress.
 Combined Steady and Variable Stress
• There are several ways in which problems involving this combination of stresses may be solved,
but the following are important from the subject point of view :

• Gerber Method
• Goodman Method
• Soderberg Method

FOR FORMULAS AND EQUATIONS

REFER PSG DESIGN DATA BOOK PAGE NO : 7.6
 Combined Steady and Variable Stress
Gerber Method: The relationship between
variable stress (σv) and mean stress (σm) for
axial and bending loading for ductile materials
are shown in Fig.
If σm is zero, σe represents the fatigue
strength for complete reversed stress.
If σe is zero, σu represents the static
ultimate strength.

where F.S. = Factor of safety,

m = Mean stress (tensile or compressive),
u = Ultimate stress (tensile or compressive), and
e = Endurance limit for reversal loading.
 Goodman Method for Combination of Stresses
• The Gerber equation being little
cumbersome to use, Goodman
proposed a simple relation as follows.
• A Goodman line is used when the
design is based on ultimate strength
and may be used for ductile or brittle
materials.
 Soderberg Method for Combination of
Stresses
• Uses yield stress in place of ultimate
tensile stress.
 Soderberg & Goodman Method for
Combination of Stresses
• Problem: A cantilever beam made of cold drawn carbon steel of circular cross-
section as shown in Fig. is subjected to a load which varies from – F to 3 F.
Determine the maximum load that this member can withstand for an indefinite
life using a factor of safety as 2. The theoretical stress concentration factor is 1.42
and the notch sensitivity is 0.9. Assume the following values
• Ultimate stress = 550 MPa
• Yield stress = 470 MPa
• Endurance limit = 275 MPa
• Size factor = 0.85
• Surface finish factor= 0.89 :
 Soderberg & Goodman Method for
Combination of Stresses
• Given : Wmin = – F ; Wmax = 3 F ; F.S. = 2 ; Kt = 1.42 ; q = 0.9 ; σu = 550 Mpa =
550 N/mm2 ; σy = 470 MPa = 470 N/mm2 ; σe = 275 MPa = 275 N/mm2 ; Ksz =
0.85 ; Ksur = 0.89
Solution:
Maximum bending moment at point A,
Mmax = Wmax × 125 = 3F × 125 = 375 F N-mm
Minimum bending moment at point A,
Mmin = Wmin × 125 = – F × 125 = – 125 F N-mm
Mean or average bending moment,
 Soderberg & Goodman Method for
Combination of Stresses
variable bending moment

Section modulus

∴ Mean bending stress

 Soderberg & Goodman Method for
Combination of Stresses
variable bending stress

Fatigue stress concentration factor, Kf = 1 + q (Kt – 1)

= 1 + 0.9 (1.42 – 1) = 1.378
Goodman’s formula
 Gerber method for Combination of Stresses

Soderberg’s formula

Taking larger of the two values, we have

F = 57.3 N Ans
 Goodman Method for Combination of Stresses
• Problem: A circular cross section C45 steel member is subjected to
an axial load that varies from -1000 N to +2500 N and to a torsional
moment that varies from 0 to +500 N-m. Assume a factor of safety
of 1.5 and a stress concentration factor of 1.5. Calculate the
required diameter of member for indefinite life.

• Given Data: Material – C45 steel; Pmax = + 2500 N; Pmin = -1000 N;

Tmax = + 500 N-m; Tmin = 0 N-m; FOS = 1.5; KT = 1.5

• To find: Shaft diameter

 Goodman Method for Combination of Stresses

• Solution:
• For C45 (PSG DB – 1.9)

• u = 630 to 710, Let u = 650 N/mm2; u = 360 N/mm2

• From (PSG DB – 1.42)
• -1 = 0.36 u = 0.36 x 650 = 234 N/mm2;
• For Repeated Twisting 0 = 0.3 u = 0.3 x 650 = 195 N/mm2
 Goodman Method for Combination of Stresses
• For Varying Axial Load

• Max Stress max = Pmax / Area = 2500 / (/4 x d2) = 3183.09 / d2

• Min Stress min = Pmin / Area = -1000 / (/4 x d2) = -1273.2 / d2

• Mean Stress mean =(max + min)/2 = 2228.16 / d2

 Goodman Method for Combination of Stresses
• For Combined Stresses (PSG DB – 7.6)
 Goodman Method for Combination of Stresses
• For Twisting
• Maximum Shear Stress

• Minimum Shear Stress min = 0

• Mean Shear Stress
 Goodman Method for Combination of Stresses
• Varying Shear Stress

• Equivalent Shear Stress (PSG DB – 7.6)

 Goodman Method for Combination of Stresses

• Combined Stress (PSG DB – 7.6)

 Goodman Method for Combination of Stresses

• To solve the equation

• Diameter of the shaft D = 29.36 mm

Reference
• Khurmi, R.S. and Gupta J.K, “Machine design ”, S.Chand publishing ,
14th Edition, 2014.
• Design of Machine Elements(Third Edition) by V B BHANDARI, Tata
McGraw Hill Education Private Limited NEW DELHI
 Design of Shaft
M.SACHIDHANANDAM
Assistant Professor
Department of Mechanical Engineering
SRM Institute of Science and Technology, Kattankulathur.
 Introduction
• Shaft is a frequent machine component which is used to transmit rotary action
or torque.
• It commonly has round cross-section and can be solid or hollow. Shafts are
supported on the bearings and transmit torque with the assist of gears, belts
and pulleys etc.
• Shafts are typically subjected to bending moment, torsion and axial pressure or
a combination of these three. So the shafts are designed relying upon the
combination of loads it is subjected to.
• Spindle stub and axle are some necessary kinds of shaft. Small shaft is
referred to as spindle. Shaft fundamental section of the prime mover is known
as stub shaft.
• An axle is a non-rotating member that contains no torque and is used to guide
rotating wheels, pulleys etc. And consequently is subjected to bending second
only.
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 Shaft Materials

• Hot-rolled plain carbon steel is the least expensive material used for shafts. These essentially
require machining to remove the scales of hot rolling process.
• Cold rolled plain carbon steel provides better yield strength and endurance strength but the cold
working induces residual stresses. Surface is smooth in this case and amount of machining
therefore is minimal. It is used for general purpose transmission shafts.
• When a shaft is to work under severe loading and corrosive conditions and require more strength,
alloy steels are used, generally having Ni, Cr, Mo and V as alloying elements.
• Alloy steels are expensive. Sometimes shafts are heat treated to improve hardness and shock
resistance and surface hardening techniques are also used if high wear resistance is the
requirement.
• As the shafts transmitting power are subjected to fatigue loading, therefore higher factor of safety
of 3 to 4 is used on the basis of yield strength for static load analysis.

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 Design of Shaft
• Shafts are designed on the basis of strength or rigidity or both. Design based on strength is to ensure that stress at any
location of the shaft does not exceed the material yield stress.

• Design based on rigidity is to ensure that maximum deflection (because of bending) and maximum twist (due to torsion)
of the shaft is within the allowable limits.

• Rigidity consideration is also very important in some cases for example position of a gear mounted on the shaft will
change if the shaft gets deflected and if this value is more than some allowable limit, it may lead to high dynamic loads
and noise in the gears.

• In designing shafts on the basis of strength, the following cases may be considered:

- Shafts subjected to torque

- Shafts subjected to bending moment

- Shafts subjected to combination of torque and bending moment

- Shafts
28/03/2024 subjected to axial loads in addition to combination
E.Muthu of torque and bending moment 46
 Shafts subjected to torque

Maximum shear stress developed in a shaft subjected to torque is given by,

where T = Twisting moment (or torque) acting upon the shaft,

J = Polar moment of inertia of the shaft about the axis of rotation
r = Distance from neutral axis to the outer most fibre = d/2 (or d o/2)

So dimensions of the shaft subjected to torque can be determined from above relation for a
known value of allowable shear stress, [].

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 Shafts Subjected to Bending Moment

Maximum bending stress developed in a shaft is given by,

Where, M = Bending Moment acting upon the shaft,

I = Moment of inertia of cross-sectional area of the shaft about
the axis of rotation
y = Distance from neutral axis to the outer most fibre = d / 2

So dimensions of the shaft subjected to bending moment can be

determined from above relation for a known value of allowable tensile
stress.
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 Shafts Subjected to Combination of
Torque and Bending Moment

• When the shaft is subjected to combination of torque and bending moment, principal
stresses are calculated and then different theories of failure are used. Bending stress and
torsional shear stress can be calculated using the above relations.

Bending Stress

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 Maximum shear stress
• Maximum shear stress is given by,

is called equivalent torque

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 Maximum principal stress
• Maximum principal stress is given by,

is called as equivalent bending moment

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 A.S.M.E. Code for Shaft Design
• According to A.S.M.E. code, the bending and twisting moment are to be multiplied by
factors kb and kt respectively, to account for shock and fatigue in operating condition.
Therefore, if the shaft is subjected to dynamic loading, equivalent torque and equivalent
bending moment will become:

According to this code, the permissible shear stress for the

shaft without keyways is taken as 30% of yield strength in
tension or 18% of the ultimate tensile strength of the material,
whichever is minimum. If keyways are present, the above
values are to be reduced by 25 per cent.

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 Design of Shaft on the basis of Rigidity

• Torsional Rigidity

For a shaft subjected twisting moment, the angle of twist is given by,

Where, T = Torque applied

L = Length of the shaft

J = Polar moment of inertia of the shaft about the axis of rotation

G = Modulus of rigidity of the shaft material

• Therefore for the known values of T, L and G and allowable value of angle of twist,
diameter of the shaft can be calculated.
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 The layout of a transmission shaft carrying two pulleys B and C and supported on
bearings A and D is shown in Fig. Power is supplied to the shaft by means of a vertical
belt on the pulley B, which is then transmitted to the pulley C carrying a horizontal belt.
The maximum tension in the belt on the pulley B is 2.5 kN. The angle of wrap for both the
pulleys is 180° and the coefficient of friction is 0.24. The shaft is made of plain carbon
steel 30C8 (Syt = 400 N/mm2) and the factor of safety is 3. Determine the shaft diameter
on strength basis.

Given:Syt = 400 N/mm2 ; factor of safety = 3; Ssy = 0.5Syt = 200 N/mm 2

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Solution:

Step1 : Calculation of Permissible Shear Stress

Step2 : Calculation of torsional moment

Torque supplied to the shaft

28/03/2024 E.Muthu 55
 Step3 : Calculation of Bending Moment

Neglecting the weight of the pulley, the downward force at the pulley B is = 3676.47 N. Similarly, the force in
the horizontal plane at the pulley C is ( + ) = 7352.94 N. The forces and bending moments in vertical and
horizontal planes are shown in Fig.
The resultant bending moment is given by,

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Step4 : Calculation Shaft Diameter

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 A transmission shaft supporting a helical gear B and an overhung bevel gear D is shown in Fig. The shaft is
mounted on two bearings, A and C. The pitch circle diameter of the helical gear is 450 mm and the
diameter of the bevel gear at the forces is 450 mm. Power is transmitted from the helical gear to the bevel
gear. The gears are keyed to the shaft. The material of the shaft is steel 45C8 (Sut = 600 and Syt = 380
N/mm2). The factors kb and kt of ASME code are 2.0 and 1.5 respectively. Determine the shaft diameter
using the ASME code.

Given:
Sut = 600 N/mm2 ; Syt = 380 N/mm2
kb = 2.0 kt = 1.5
For gears, (dp)B = 450mm
(dp)D = 450mm

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Solution:
Step1 : Permissible shear stress

The lower of the two values is 108 N/mm2 and there are keyways on the
shaft.

Step2 : Bending Moment

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Step3 : Torsional Moment

Step4 : Shaft Diameter

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 A transmission shaft supporting a helical gear B and an overhung bevel gear D is shown in Fig. The shaft is
mounted on two bearings, A and C. The pitch circle diameter of the helical gear is 450 mm and the
diameter of the bevel gear at the forces is 450 mm. Power is transmitted from the helical gear to the bevel
gear. The gears are keyed to the shaft. The material of the shaft is steel 45C8 (Sut = 600 and Syt = 380
N/mm2). The factors kb and kt of ASME code are 2.0 and 1.5 respectively. Determine the shaft diameter
using the ASME code. For this shaft, the permissible angle of twist is 0.25° per metre length.
The modulus of rigidity for the shaft material is 79 300 N/mm2. Calculate:
(i) the permissible angle of twist between helical and bevel gears; and
(ii) the shaft diameter on the basis of torsional rigidity.
Compare the results with the based on strength and comment on the results.

Given:
Sut = 600 N/mm2 ; Syt = 380 N/mm2
kb = 2.0 kt = 1.5
For gears, (dp)B = 450mm
(dp)D = 450mm
= 0.25° per metre

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Solution:

Step1 : Permissible angle of twist

The portion of the shaft between the two gears is subjected to twisting. The
distance between the helical gear B and the bevel gear D is 800 mm

Step2 : Diameter of Shaft

𝑀 𝑡 =640 x 225=144000 𝑁𝑚𝑚

The shaft was designed on the basis of its strength

and its diameter was calculated as 32.95 mm. On
the basis of torsional rigidity, the diameter comes
out to be 45.38 mm. Therefore, it is necessary to
design the shaft on the basis of strength as well as
rigidity.
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 References
• Design of Machine Elements 4th edition VB Bhandari

• Analysis and Design of Machine Elements VK Jadon

• A Text Book of Machine Design RS Khurmi

• Mechanical Engineering Design 8th edition JE Shigley

• Design of Machine Elements vol. I 2 nd edition T Krishna Rao

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Design of keys and couplings
 Variable stresses,
design of shafts, keys and couplings
1. Design of keys:
 Types of keys,
 forces acting on a key

2. Couplings:
 Types of couplings, design of sleeve coupling and clamp coupling.
 Design of Flange coupling
 Design of bushed pin Flexible coupling
 Tutorial – Problems on coupling

28/03/2024 Kumaran D 65
 Keys
Introduction:
• A key is a piece of mild steel inserted
between the shaft and hub or boss of
the pulley to connect these together in
order to prevent relative motion
between them.
• It is always inserted parallel to the axis
of the shaft.
• Keys are used as temporary fastenings
and are subjected to considerable
crushing and shearing stresses.
• A keyway is a slot or recess in a shaft
and hub of the pulley to accommodate
a key.
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Types of Keys
The following types of keys are important from the subject point of view :
1. Sunk keys, 2. Saddle keys, 3. Tangent keys, 4. Round keys, and 5. Splines.

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Gib-head key. It is a rectangular sunk key with a head at one end known as gib head. It is usually
provided to facilitate the removal of key. A gib head key is shown in Fig. (a) and its use in shown in Fig.
(b).

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Feather key. A key attached to one member of a pair and which permits relative axial movement is known as
feather key. It is a special type of parallel key which transmits a turning moment and also permits axial movement.
It is fastened either to the shaft or hub, the key being a sliding fit in the key way of the moving piece.

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Woodruff key. The woodruff key is an easily adjustable
key. It is a piece from a cylindrical disc having segmental
cross-section in front view as shown in Fig. A woodruff
key is capable of tilting in a recess milled out in the shaft
by a cutter having the same curvature as the disc from
which the key is made. This key is largely used in
machine tool and automobile construction.

Saddle keys
The saddle keys are of the following two types :
1. Flat saddle key, and 2. Hollow saddle key.
A hollow saddle key is a taper key which fits in a
keyway in the hub and the bottom of the key
is shaped to fit the curved surface of the shaft. Since
hollow saddle keys hold on by friction, therefore
these are suitable for light loads. It is usually used as a
temporary fastening in fixing and setting
eccentrics, cams etc.

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Tangent Keys
The tangent keys are fitted in pair at right angles as shown in
Fig. Each key is to withstand torsion in one direction only.
These are used in large heavy duty shafts.

Round Keys
The round keys, as shown in Fig. (a), are circular in section and
fit into holes drilled partly in the shaft and partly in the hub.
They have the advantage that their keyways may be drilled and
reamed after the mating parts have been assembled. Round keys
are usually considered to be most appropriate for low power
drives.

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Splines
Sometimes, keys are made integral with the shaft which fits in
the keyways broached in the hub. Such shafts are known as
splined shafts as shown in Fig.

These shafts usually have four, six, ten or sixteen splines. The
splined shafts are relatively stronger than shafts having a single
keyway.
The splined shafts are used when the force to be transmitted is
large in proportion to the size of the shaft as in automobile
transmission and sliding gear transmissions. By using splined
shafts, we obtain axial movement as well as positive drive is
obtained.

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Forces acting on a Sunk Key
When a key is used in transmitting torque from a shaft to a rotor
or hub, the following two types of forces act on the key :
1. Forces (F1) due to fit of the key in its keyway, as in a tight fitting straight key or in a tapered key driven in place.
These forces produce compressive stresses in the key which are difficult to determine in magnitude.
2. Forces (F) due to the torque transmitted by the shaft. These forces produce shearing and compressive (or crushing)
stresses in the key. The distribution of the forces along the length of the key is not uniform because the forces are
concentrated near the torque-input end. The non-uniformity of distribution is caused by the twisting
of the shaft within the hub. The forces acting on a key for a clockwise torque being transmitted from a shaft to a hub
are shown in Fig.

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 Design the rectangular key for a shaft of 50
mm diameter. The shearing and crushing
stresses for the key material are 42 MPa and
70 MPa.

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 PSG DB 5.16

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A 45 mm diameter shaft is made of steel
problem
with a yield strength of 400 MPa. A
parallel key of size 14 mm wide and 9 mm
thick made of steel with a yield strength of
340 MPa
is to be used. Find the required length of
key, if the shaft is loaded to transmit the
maximum
permissible torque. Use maximum shear
stress theory and assume a factor of safety
of 2.
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 problem

A 15 kW, 960 r.p.m. motor has a mild steel

shaft of 40 mm diameter and the extension
being 75 mm. The permissible shear and
crushing stresses for the mild steel key
are56 MPa and 112 MPa. Design the
keyway in the motor shaft extension.
Check the shear strength of the key against
the normal strength of the shaft.
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 Couplings
Types of couplings, design of sleeve coupling and clamp coupling.
Design of Flange coupling
Design of bushed pin Flexible coupling
Tutorial – Problems on coupling
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 Tutorial Problem

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A flange coupling usually applies to a
coupling having two separate cast iron
flanges. Each flange is mounted on the
shaft end and keyed to it. The faces are
turned up at right angle to the axis of
the shaft. One of the flange has a
projected portion and the other flange
has a corresponding recess.

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1. Unprotected type flange
coupling. In an unprotected type
flange coupling, as shown in Fig.
13.12, each shaft is keyed to the boss
of a flange with a counter sunk key
and the flanges are coupled together
by means of bolts. Generally, three,
four or six bolts are used. The keys
are staggered at right angle along the
circumference of the shafts in order
to divide the weakening effect caused
by keyways.
The usual proportions for an unprotected type cast iron
flange couplings, as shown in
Fig. 13.12, are as follows :
If d is the diameter of the shaft or inner diameter of the
hub, then
Outside diameter of hub,
D=2d

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 References
R S Khurmi & Gupta, Machine Design, EURASIA PUBLISHING HOUSE (PVT.) LTD.
2005

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